TOYOTA AVENSIS 2002 Repair Manual

A60622
A79324
A76713
A64023
14±82
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
14.DISCONNECT FUEL TUBE SUB±ASSY (See page 11±11) SST09268±21010
15.DISCONNECT UNION TO CONNECTOR TUBE HOSE
(a)Disconnect the union to connector tube hose from the hose to hose tube.
16.DISCONNECT RADIATOR HOSE INLET
(a)Disconnect radiator hose inlet from the cylinder head.
17.DISCONNECT HEATER INLET WATER HOSE
(a)Disconnect the heater inlet water hose from the cylinder head.
18.REMOVE FAN AND GENERATOR V BELT
(a)Turn the V±ribbed belt tensioner clockwise slowly andloosen it. Remove the fan and generator V belt and put
back the V±ribbed belt tensioner carefully.
19.REMOVE V±RIBBED IDLER ASSY NO.1
(a)Remove the nut, bolt, tube and idler.
20.REMOVE GENERATOR ASSY (See page 19±7)
21. DISCONNECT IGNITION COIL ASSY
(a) Remove the 5 clamps from the 5 clamp brackets.
(b) Disconnect the 4 ignition coil connectors.
(c) Remove the 2 nuts which are used to secure the engine wire.
(d) Remove the 4 bolts and the 4 ignition coils.

A65078
A64058
A79363
A64026
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±83
AVENSIS REPAIR MANUAL (RM1018E)
22. DISCONNECT VENTILATION HOSE
(a) Disconnect the ventilation hose from the cylinder head
cover.
23. DISCONNECT VENTILATION HOSE NO.2
(a) Disconnect the ventilation hose from the cylinder head
cover.
24. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water hoses from the throttle body.
(b) Disconnect the ventilation hose and ventilation hose No.
2 from the cylinder head cover.
(c) Disconnect the vacuum hose from the water by±pass
pipe No. 1.
(d) Remove the 4 bolts, 2 nuts and 2 wire brackets.
(e) Remove the intake manifold and the throttle body assem-
bly.
(f) Remove the gasket from the intake manifold and the
throttle body assembly.
25. REMOVE OIL LEVEL GAGE SUB±ASSY
(a) Remove the oil level gage from the oil level gage guide.
26. REMOVE OIL LEVEL GAGE GUIDE
(a) Disconnect the crankshaft position sensor cramp.
(b) Remove the bolt and the oil level gage guide.
27. SEPARATE WATER BY±PASS PIPE NO.1
(a) Remove the 2 bolts which are used to secure the water
by±pass pipe.

B06777
A76720
A76721
A01045
A64005
14±84
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
28. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE
ASSY
(a) Remove the bolt and the camshaft timing oil control valve.
29. SEPARATE EXHAUST PIPE ASSY FRONT
(a) Remove the 2 bolts and 2 compression springs which are
used to secure the front side of exhaust pipe.
(b) Remove the gasket.
30. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and the manifold stay.
31. REMOVE MANIFOLD STAY NO.2
(a) Remove the 3 bolts and the manifold stay No. 2.
32. REMOVE ENGINE MOUNTING INSULATOR
SUB±ASSY RH
(a) Place a wooden block on a jack underneath the engine.
Remove the 4 bolts and 2 nuts and detach the engine
mounting insulator RH.

A64856
A62185
MarkMark
Mark Timing Chain
Cover Surface
Timing
Notch
A62837SST
A11858
±
ENGINE MECHANICAL CYLINDER HEAD GASKET(1ZZ±FE/3ZZ±FE)
14±85
AVENSIS REPAIR MANUAL (RM1018E)
33.REMOVE CYLINDER HEAD COVER SUB±ASSY
(a)Remove the 9 bolts, 2 seal washers, 2 nuts and 3 clamp
brackets.
(b)Remove the cylinder head cover.
34.SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a)Turn the crankshaft pulley to align the timing notch with the timing mark º0º of the timing chain cover.
(b)Check that the point marks of the camshaft timing sprock- et and VVT timing sprocket are in straight line on the tim-
ing chain cover surface as shown in the illustration.
HINT:
If not, turn the crankshaft 1 revolution (360
) and align the
marks as above.
35.REMOVE CRANKSHAFT PULLEY
(a)Using SST, remove the pulley bolt. SST09960±10010 (09962±01000, 09963±01000)
(b)Remove the crankshaft pulley from the crankshaft.
36.REMOVE V±RIBBED BELT TENSIONER ASSY
(a)Remove the bolt and nut and detach the V±ribbed belt tensioner.
HINT:
Jack up and down to remove the bolt.
37.REMOVE WATER PUMP ASSY(See page 16±9)

A12816
A76692
A62178
Push
A10076
A30848
14±86
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
38. REMOVE TRANSVERSE ENGINE ENGINE
MOUNTING BRACKET
(a) Remove the 3 bolts and the transverse engine engine
mounting bracket.
39. REMOVE CRANKSHAFT POSITION SENSOR
(a) Remove the 2 bolts which are used to secure the crank-
shaft position sensor.
40. REMOVE CHAIN TENSIONER ASSY NO.1
(a) Remove the 2 nuts and the chain tensioner.
NOTICE:
Do not revolve the crankshaft without the chain tensioner.
41. REMOVE TIMING CHAIN OR BELT COVER
SUB±ASSY
(a) Remove the 11 bolts and nuts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying between the cyl-
inder head and the cylinder block with a screwdriver.
NOTICE:
Be careful not to damage the timing chain cover, the cylin-
der head and the cylinder block.
42. REMOVE TIMING GEAR COVER OIL SEAL
(a) Using a screwdriver, remove the oil seal.
43. REMOVE CRANKSHAFT POSITION SENSOR PLATE
NO.1
44. REMOVE CHAIN TENSIONER SLIPPER
(a) Remove the bolt and the chain tensioner slipper.
45. REMOVE CHAIN VIBRATION DAMPER NO.1
(a) Remove the 2 bolt and the chain vibration damper.

A30857
A62814
4 2531
A62816
2
5 3
110 8 4 796
A62827
Lot No.
A62820
Overall Length
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±87
AVENSIS REPAIR MANUAL (RM1018E)
46. REMOVE CHAIN SUB±ASSY
(a) Remove the timing chain by prying the crankshaft timing
gear using screwdrivers as shown in the illustration.
NOTICE:

Put shop rag to protect the engine.

In case of revolving the camshafts with the chain off
the sprockets, turn the crankshaft 1/4 revolution
counterclockwise to prevent the valves from touch-
ing the pistons.
47. REMOVE CAMSHAFT
(a) Using several steps, loosen and remove the 19 bearing
cap bolts uniformly in the sequence shown in the illustra-
tion. Remove the 9 bearing caps, and both the intake and
exhaust camshafts.
48. REMOVE CYLINDER HEAD SUB±ASSY
(a) Using several steps, loosen and remove the 10 cylinder
head bolts with a 10 mm hexagon wrench uniformly in the
sequence shown in the illustration. Remove the 10 cylin-
der head bolts and 10 plate washers.
(b) Remove the cylinder head.
49. REMOVE CYLINDER HEAD GASKET
50. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket on the cylinder block
with the Lot No. stamp facing upward.
NOTICE:

Pay attention to the mounting orientation.

Place the cylinder head on the gasket gently in order
not to damage the gasket with the bottom part of the
head.
51. INSPECT CYLINDER HEAD SET BOLT
(a) Using a vernier calipers, measure the length of cylinder
head bolt from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 in.)
Maximum length: 148.5 mm (5.846 in.)
If the length exceeds the maximum, replace the bolt.

A62816
84 2 59
7 3 1 6 10
A62823
Paint Mark
90

Front
A62150
Camshaft No. 2
Camshaft
A62825
62 4 8
51 3 7 11
10
9
A10079
14±88
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
52. INSTALL CYLINDER HEAD SUB±ASSY
HINT:
The cylinder head bolts are tightened in 2 successive steps.
(a) Apply a light coat of engine oil on the threads of the cylin-
der head bolts.
(b) Using several steps, install and tighten the 10 cylinder
head bolts and plate washers with a 10 mm hexagon
wrench uniformly in the sequence shown in the illustra-
tion.
Torque: 49 N
m (500 kgf
cm, 36 ft
lbf)
(c) Mark the front of the cylinder head bolt with paint.
(d) Retighten the cylinder head bolts 90
in the same se-
quence as step (b).
(e) Check that the paint mark of each bolt is at 90
angle to
the front.
53. INSTALL CAMSHAFT
(a) Apply a light coat of engine oil on the camshaft journals.
(b) Place the 2 camshafts on the cylinder head as shown in
the illustration.
(c) Examine the front marks and numbers and tighten the
bolts in the sequence shown in the illustration.
Torque:
23 N
m (235 kgf
cm, 17 ft
lbf) for Bearing cap No. 1
13 N
m (133 kgf
cm, 10 ft
lbf) for Bearing cap No. 3
54. INSTALL CHAIN SUB±ASSY
(a) Set No. 1 cylinder to TDC/compression.
(1) Turn the camshafts using a wrench to align the tim-
ing marks of the 2 camshaft timing sprockets.

A62170
Set KeyUpward
A62171
Yellow
Color Link
Timing Mark
A62172
SST
A62173
Yellow Color Mark
Timing Mark
A30867
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±89
AVENSIS REPAIR MANUAL (RM1018E)
(2) Using a crankshaft pulley bolt, turn the crankshaft
and set the set key on the crankshaft upward.
(b) Install the timing chain on the crankshaft timing sprocket
with the yellow color link and the timing mark on the crank-
shaft timing sprocket aligned.
HINT:
Three yellow color links are on the chain.
(c) Using SST, install the crankshaft timing sprocket.
SST 09223±22010
(d) Install the timing chain to the camshaft timing sprockets
with the yellow color links and the timing marks on the
camshaft timing sprockets aligned.
55. INSTALL CHAIN VIBRATION DAMPER NO.1
(a) Install chain vibration damper with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
56. INSTALL CHAIN TENSIONER SLIPPER
(a) Install the chain tensioner slipper with the bolt.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
57. INSTALL CRANKSHAFT POSITION SENSOR PLATE
NO.1
(a) Install the plate with the ºFº mark facing forward.

A62174
SST
A62175
Seal Width
4 to 5 mm
Seal Packing
A65676
Timing Chain Cover side:
3 (0.118)3 (0.118)
A
ABB
C
C
7 (0.276)
4.5 (0.177)
12 (0.472)6 (0.236)
3 (0.118)
Width 4 (0.157)
A ± AB ± B
C ± C
08826±00100 or equivalent
08826±00080 or equivalent
(mm (in.)) 14±90
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
58. INSTALL TIMING GEAR COVER OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST, tap in the oil seal until its surface is flush with
the timing chain cover edge.
SST 09223±22010
NOTICE:
Keep the lip free of foreign objects.
59. INSTALL TIMING CHAIN OR BELT COVER SUB±ASSY
(a) Remove any old packing material (FIPG) from the contact
surface.
(b) Apply a continuous bead of seal packing (Diameter 3.5
mm to 4.5 mm (0.1379 to 0.177 in.)) as shown in the il-
lustration.
Seal packing:
Water pump part part No. 08826±00100 or equivalent
Other part part No. 08826±00080 or equivalent.
NOTICE:

Remove any oil from the contact surface.

Install the oil pan within 3 minutes after applying seal
packing.

Do not expose the seal to engine oil within 2 hours af-
ter installing.

A65677
A
A
AA
A
A
AAA B
B
B
A62177
Raise
Push
Hook
Pin
A62178
Push
A76692
± ENGINE MECHANICALCYLINDER HEAD GASKET (1ZZ±FE/3ZZ±FE)
14±91
AVENSIS REPAIR MANUAL (RM1018E)
(c) Install the timing chain cover with the 11 bolts and nut.
Torque:
13 N
m (133 kgf
cm, 10 ft
lbf) for A
19 N
m (194 kgf
cm, 14 ft
lbf) for B
(d) Using a torx wrench socket (E8), install the stud bolt.
Torque: 9.5 N
m (97 kgf
cm, 84 in.
lbf)
60. INSTALL CHAIN TENSIONER ASSY NO.1
(a) Check that the O±ring is clean, and set the hook as shown
in the illustration.
(b) Apply engine oil to the chain tensioner and install it with
the 2 nuts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
NOTICE:
If the hook released the plunger during installation, re±
hook the plunger by the hook to fix it.
61. INSTALL CRANKSHAFT POSITION SENSOR
(a) Apply a light coat of the engine oil to the O±ring on the
crankshaft position sensor.
(b) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)